Process for forming a heat stable sausage emulsion

ABSTRACT

AN EMULSIFICATION PROCESS FOR THE FORMING OF A HEATSTABLE SAUSAGE EMULSION EMPLOYS FIRST AN ABRADING AND CUTTING OPERATION ON A SLURRY OF MEAT PROTEIN, FAT, WATERS AND SALT, AND AFTER SALT-SOLUBLE PROTEIN HAS BEEN EFFECTIVELY EXTRACTED, THE SLURRY MIXTURE IS SUBJECTED TO A CUTTING AND DISPERSING ACTION WITHOUT ABRASION TO BRING THE FAT INTO DISCONTINUOUS PHASE SO THAT IT MAY BE EFFECTIVELY COATED WITH THE SALT-SOLUBLE PROTEIN. IN THE FOREGOING OPERATION, BINDER PORTEIN IN MEAT IS EXPOSED BY THE ABRADING OR RUPTURING OF THE MEMBRANE COVERING THE BINDER PROTEIN FOR THE EFFECTIVE AND SPEEDY USE OF THE SALT IN EXTRACTING BINDER PROTEIN, BUT DURING THE ABRASIVE AND CUTTING   STEP, THE FAT IS PRESSED INTO FILM OR SMEAR FORM, THUS PLACING IT SUBSTANTIALLY IN CONTINUOUS PHASE, AND THE FOLLOWING STEP OF CUTTING AND DISPERSING WITHOUT ABRASION IS EFFECTIVE IN DISTRIBUTING THE FATE IN FINE PARTICLE FORM SO THAT IT IS READILY COATED WITH THE BINDER PROTEIN.

Feb. 23, 1971 o, ARTAR 3,565,637

PROCESS FOR FORMING A HEAT STABLE SAUSAGE EMULSION Filed March 7 1968 3Sheets-Sheet 1 FIGI TO VAC.

INVENTORS: ORHAN G. ARTAR MILLARD J. HAFSTAD BY: Q45

ATT'Y Feb. 23, 1971 ARTAR 3,565,637

PROCESS FOR FORMING A HEAT STABLE SAUSAGE EMULSION Filed March 7, 1968 5Sheets-Sheet 2 FIGS l/\/'VIi/ /'I()RS: ORHAN G. ARTAR WILLARD J. HAFSTADFeb. 23, 1971 o. G. ARTAR 3,565,637

PROCESS FOR FORMING A HEAT STABLE SAUSAGE EMULSION Filed March '7, 19683 Sheets-Sheet 5 INVENTORS. ORHAN G. ARTAR MILLARD J. HAFSTAD Q16 C an?ATT'Y United States Patent ()Pfice 3,565,637 Patented Feb. 23, 19713,565,637 PROCESS FOR FORMING A HEAT STABLE SAUSAGE EMULSION Orhan G.Artar, Evanston, Ill., and Millard J. Hafstad,

Detroit Lakes, Minn., assignors to Armour and Company, Chicago, 111., acorporation of Delaware Filed Mar. 7, 1968, Ser. No. 711,439 Int. Cl.A22c 11/00; B02c 18/00 US. Cl. 99-109 3 Claims ABSTRACT OF THEDISCLOSURE An emulsification process for the forming of a heatstablesausage emulsion employs first an abrading and cutting operation on aslurry of meat protein, fat, water and salt, and after salt-solubleprotein has been effectively extracted, the slurry mixture is subjectedto a cutting and dispersing action without abrasion to bring the fatinto discontinuous phase so that it may be etfectively coated with thesalt-soluble protein. In the foregoing operation, binder protein in meatis exposed by the abrading or rupturing of the membrane covering thebinder protein for the effective and speedy use of the salt inextracting binder protein, but during the abrasive and cutting step, thefat is pressed into film or smear form, thus placing it substantially incontinuous phase, and the following step of cutting and dispersingwithout abrasion is effective in distributing the fat in fine particleform so that it is readily coated with the binder protein.

BACKGROUND AND SUMMARY Binder protein, which primarily consists ofprotein called myosin, in red, lean meat is contained in a subunit ofmuscle called a muscle fiber. The muscle fiber has a protective membranewhich ordinarily prevents the salt from effectively reaching the binderprotein and thus extracting or solubilizing all of the available binderprotein. Even when the meat is finely cut by hand or by a machine suchas a chopper or a Mincemaster, the membranes still block access to somebinder protein. However, by employing a pressing or abrading force alongwith the cutting action, We find that the membranes can be ruptured toprovide ready access of the salt to the binder protein.

This action also results in pressing the fat into smear form. In thisform, the fat is substantially in continuous phase and the mixture doesnot constitute a sufficiently stable emulsion because the binder proteincannot coat effectively such fat material.

We have discovered that the mixture or slurry can be changed into astable emulsion by cutting and dispersing it, without abrasion, todistribute the fat in small particles and in a discontinuous phasethroughout the body so that the binder protein can readily coat theparticles.

DRAWINGS In the accompanying drawings, FIG. 1 is a broken side elevationof a commercial machine known in the trade as the Comvac machine, FIG.2, an enlarged sectional view of the cutting heat shown in FIG. 1; FIG.3, a broken plan view of the plate assembly structure shown in the lowerportion of FIG. 2; FIG. 4, a broken vertical sectional view of acommercial machine which is known in the trade by the name Mincemaster;and FIG. 5, a broken detail sectional view of the knife and perforatedplate structure shown in FIG. 4 showing the knife edge in shearingposition and in contact with the top of the perforated plate.

DETAILED DESCRIPTION In FIGS. 1, 2 and 3, which purport to show thecommercial machine known as the Comvac machine, a casing 10 provides achamber for receiving the slurry or material which is to be treated.Above the chamber is supported a bearing 11 in which is mounted a drivenshaft 12. The slurry or other material to be introduced into the chamberis passed through conduit 13 and onto a cutting head which is made up ofa number of plates. In the cutting head, the lowermost plate 14 is astationary plate and is provided with perforations. Above the plate 14is a driven plate 15 which is also provided with cutting perforations.Above the plate 15 is a stationary plate 16 provided also withperforations. Finally, above fixed plate 16 is a driven discharge plate17. A spacer ring 18 is interposed between a bottom plate 20 fixed uponthe end of shaft 12 and the driven plate 15, as shown best in FIG. 2,and a spacer ring 19 is interposed between the driven plate 15 and thedischarge plate 17. The spacer rings 18 and 19 provide clearancesbetween the plates and the clearances are important in that an abradingaction in addition to a cutting action results when the slurry materialis passed through the plates. The driven plates 15 and 17 are driventhrough the bottom plate 20 fixed upon shaft 12 and through driving pins21 which extend through the plate 20 and through plates 15 and 17, asshown in FIG. 2.

The fixed plate 16 is provided about its periphery withinwardly-extending notches 16a and projections 19a from the casing 10extend into the notches and hold the plate against rotation, as shownbest in FIGS. 2 and 3. Similarly, projections 18w engage like notches inplate 14 and anchor it against rotating. Plates 14 and 16 are cut awayalong their inner edges so that they do not contact the driving pins 21.In this cut-away area the pins carry the spacers 18 and 19 which arehigher than the plates 14 and 16 and thus provide a space between thestationary plate 14 and driven plate 15 and the stationary plate 16 anddriven member or plate 17. It is this slight spacing which brings aboutthe squeezing or abrading action above described and which, in additionto the cutting action afforded by the slots in the plates, ruptures themembranes.

Since the structure shown in FIGS. l-3 is well known, a further detaileddescription is believed unnecessary.

The slurry passes through conduit 13 and thence downwardly centrally ofthe cutting head and upwardly through the perforated plates andoutwardly from the discharge plate 17. The apparatus is unusuallyeffective by reason of the clearances between the plates in exerting anabrading as well as the cutting action on the slurry material as itpasses through the head.

In the structure shown in FIG. 4, the casing 22 provides a chamberthrough which the slurry of material is passed over a fixed perforatedplate 23 above ejector member 26. A driven shaft 24 carries a rotatingknife 25 having its edge which contacts the plate so as to cut thematerial through the plate without any abrading action. The ejectormember 26 mounted on the rotating shaft 24 receives the material passingthrough the perforated plate 23 and discharges the material throughconduit 27.

As shown best in FIG. 5, the knife 25 has its cutting edge 25a bearingagainst the surface of the fixed perforated plate 23 so as to cutwithout squeezing or smearing the material fed to plate 23, and afterthe sheared material passes through the plate 23 it is quickly carriedaway through outlet 27. Since the machine is well known in the industry,a further detailed description is believed unnecessary.

The slurry mixture may be prepared in any suitable manner, as by mixingmeat protein, fat, water and salt, together with the usual spices andcure. The mixture may be chopped or comminuted in any suitable orconventional manner, or, if desired, the process may be started withmeat already ground which is mixed with salt, water and spices.

The lean meat, from which the desired binder protein is to be extracted,presents a problem in that the muscle and particularly the muscle fibersare enclosed by protective membranes which restrict access of the saltto the binder protein. By passing the mixture through an abrading aswell as cutting mechanism, it is found that the membranes are rupturedand this allows quick action of the salt upon the binder protein. Vacuummay also be employed to increase the density of the material. Theabrasive action has also an effect upon the fat, pressing the fat intocontinuous phase so that it has a film or smear form. An advantage hasbeen achieved in that binder protein has been efficiently extracted andis available, but there is a disadvantage in that the fat issubstantially distributed in continuous form.

By subjecting the slurry or mixture to a cutting and dispersing actionwhile avoiding abrasion, the fat is changed from the smear configurationto fine particles, while at the same time the mixture is rotated ormoved to intimately mix the fine particles of fat with the binderprotein so that effective coating of the particles by the protein isbrought about. When the emulsion thus produced is subjeced to heatingtests to determine its stability, it is found that the emulsion ishighly stable, releasing a minimum of fat in the cooking operation.

While the initial emulsion mixture can be formed in any suitable way, weprefer to mix the red or lean muscle meat, fat, water, salt and spicesand we obtain a temperature of about 38-52 F. (preferably about 40-50"F.). The mixture maybe chopped or comminuted in the presence of water,ice or, if a faster operation is desired, in the presence of warm or hotwater. The best results have been obtained when the temperatures areabout 44-48 F. The mixture is then subjected to a cutting and abradingaction, and for this purpose any suitable apparatus may be used. Theancient flour-making process, in which grinding stones bear upon grainwhich is to be pulverized by rotating the stones, may be employed, butWe prefer to employ modern apparatus in which spaced plates havingorifices through the plates providing cutting edges are used so thatabrasion and cutting are accomplished in one operation as shown inFIG. 1. Such an operation is shown in U.S. Pat. No. 3,221,788 and isdescribed as a comminutor-vacuumizer unit. Rotating plates which have aslight clearance between the plates provide an abrasive effect upon themuscle particles as the plates rotate, while at the same time holesthrough the plates provide cutting edges for comminuting the meatmaterial. It will be understood that the rupturing of the membranes andthe cutting of the meat body can be accomplished manually, but we preferto employ known apparatus of the foregoing type for rupturing themembranes of the muscle and exposing the binder protein to the action ofthe salt.

The abrading and cutting operation may be carried out at any suitabletemperature. We prefer, however, to carry through the operation with amixture having a temperature in the range of about 38-56 F. During theabrading and cutting operation, it is found that the temperature risesusually about -15 F.

In the final operation in which the mixture is treated to distribute thefat in discontinuous phase, we may employ any suitable means orapparatus. The mixture may be cut and mixed with cutting tools so as tobreak up and disperse the fat smears into particles and without abrasiveaction. We find that this action can be carried out effectively bywell-known apparatus, such as the Mincemaster as shown in FIG. 2. Thisknown device consists of fixed plate apparatus in which rotating knivesare held against the plate so as to cut the material passing throughopenings in the plate and without any abrading action. Since theMincemaster is well known, a further detailed description herein isbelieved unnecessary. It will be un- 4 derstood that any apparatus, suchas a perforated plate through which the slurry is passed while bringingknives across the plate in contact with the plate for the severingaction, may be used.

The final cutting and dispersing action, without abrasion, may becarried on at any suitable temperature, but we find that a startingtemperature of about 5266 F. gives the best results.

In the final operation, fat is distributed in fine particles that aresurrounded by efficiently solubilized binder protein which forms aneffective barrier around the said fat particles so that a surprisinglysmall amount of the fat is released later in the heat-testing procedure.We believe that this is accomplished by the movement of the material inthe Mincemaster or other apparatus when the material is being passedthrough the fine openings and severed as above described.

The stable emulsion prepared as described above may be employed inpreparing finely-comminuted sausage products, such as, for example,bologna, frankfurters, braunschweiger, and other types of liver sausage,pickle loaf, olive loaf, etc.

The combination of steps in which the comminutorvacuumizer unit, such asthat described in Pat. No. 3,221,- 788 and known commercially as Comvac,followed by pasing the material through a Mincemaster, enables us to usemeat mixtures of high fat content by weight, as, for example, thefollowing:

Percentage Meat Emulsion Product er 53-57 44-52 Salt, flavorings, etc8-4 5 6 By way of specific example, the product composition may be 10percent protein, 35 percent fat, 50 percent Water, and 5 percent salt,flavorings, etc.

In the abrading and cutting operation carried on by thecomminutor-vacuumizer unit, the mixture may be subjected to vacuum forthe removal of trapped air and to increase the density of the mixture.

Specific examples illustrative of the process may be set out as follows:

Other ingredients consisted of all meat bologna flavorings, salt, cure,sodium erythorbate and water.

Emulsion preparation procedure Was as follows:

All formula ingredients were mixed together and placed in a chopper.Temperature of the mix at this time was 38 F. Following a 1 minute chop,the mix was unloaded at a temperature of 50 F. and passed through thecomminutor-vacuumizer unit (Comvac). The mix was unloaded from this unitand passed through a Mincemas ter. Temperature of the mix from thecomminutor-vacuumizer was 62 F. Temperature of finished emulsion fromthe Mincemaster was 68 F.

The finished emulsion was then stuffed and processed in the conventionalmanner.

Separate samples of the mix from the chopper and comminutor-vacuumizerand finished emulsion sample from the Mincemaster were subjected to anemulsion stability test.

The emulsion stability test consists of a determination of the amount offat released from an emulsion mix upon heating under controlledconditions in a test tube. Fat in the amount of .3 ml. or less indicatesthat the emulsion will process satisfactorily, meaning that fat isemulsified to a great extent and that there will be little or no freefat in the product. As the amount of fat released in the test tubeincreases, the amount of free fat in the product will increase,resulting in poor quality or unsalable product, depending on thequantity of fat released.

The results of the stability tests were as follows:

Amount of fat released, ml. Sample from Chopper (1) 6.3 Comvac (1) .7Comvac (2) .8 Mincemaster 1) .2 Mincemaster (2) .3

Fat content of the finished product was 35.5 percent.

Example II A weak formula was used for this test, which was as follows:

Lbs. Boneless beef platesfrozen 400 Frozen beef heartshard chilled 100Other ingredients consisted of all meat bologna flavorings, salt, cure,sodium erythorbate and water.

Emulsion preparation procedure was as follows:

All formula ingredients were mixed together and placed in a chopper.Temperature of the mix at this time was 32 F. Following a 1% minutechop, the mix was unloaded at a temperature of 49 F. and passed throughthe comminutor-vacuumizer unit. The mix was unloaded from this unit andpassed through a Mincemaster. Temperature of the mix from thecomminutor-vacuumizer was 59 F. Temperature of finished emulsion fromthe Mincemaster was 67 F.

The finished emulsion was then stuffed and processed in a conventionalmanner.

Separate samples of the mix from the chopper and comminutor-vacuumizerand finished emulsion sample from the Mincemaster were subjected to anemulsion stability test. The results of this test were as follows:

Sample from-- Amount of fat released, ml.

Chopper (1) 9.5 Comvac (1) 9.3 Comvac (2) 9.3 Mincemaster (1) .9Mincemaster (2) .9

Fat content of the finished product was 37.0 percent.

While the final product exceeded the test results described in ExampleI, the foregoing illustrates the marked improvement of the product byusing the Mincemaster following the Comvac operation.

Example III This test illustrates a case where the use of a Mincemasteris not included in the emulsion preparation procedure.

Meat formula for this test consisted of the following:

Lbs. Lean picnic trimmingsfresh 37 Boneless beef platesfresh 145 Beefheartsfresh 3O Belly strips-fresh 38 Other ingredients consisted of allmeat bologna fiavorings, salt, cure, sodium erythorbate and water.

Emulsion preparation procedure was as follows:

Formula ingredients (except 40 percent of water in the form of ice) werechopped in a chopper to 55 F. The remaining ice was added to the mix andthe mix was unloaded from the chopper at 41 F. and passed through thecomminutor-vacuumizer unit and transferred to a stuffer. The stuffedproduct was then processed in a con ventional manner.

Separate samples from the chopper and comminutorvacuumizer weresubjected to a stability test. The results of these tests were asfollows:

Sample from- Amount of fat released, ml.

Chopper (1) 5.5 Chopper (2) 5.2 Comvac (1) 1.8 Comvac (2) 1.8

Fat content of the finished product was 32.8 percent. The above testshows that the productobtained from the Comvac alone was unsatisfactory.

Example IV Meat formula for this test consisted of the following:

Cow meat-frozen Boneless beef plates-frozen Beef cheeks-frozen 100 Porkjowlsfrozen 150 Other ingredients consisted of all meat frankfurterfiavorings, salt, cure, sodium erythorbate and water.

Emulsion preparation procedure was as follows:

All formula ingredients were mixed together and placed in a chopper.Temperature of the mix at this time was 40 F. Following a 2-minute chop,the mix was unloaded at a temperature of 48 F. and passed through thecomminutor-vacuumizer unit. The mix was unloaded from this unit andpassed through a Mincemaster. Temperature of the mix from thecomminutor-vacuumizer was 58 F. Temperature of finished emulsion fromthe Mincemaster was 66 F.

The finished emulsion was then stuffed, linked, and processed in aconventional manner.

Separate samples of the mix from the chopper and comminutor-vacuumizerand finished emulsion sample from the Mincemaster were subjected to anemulsion stability test. The results of this test were as follows:

Sample from Amount of fat released, rnl.

Chopper (1) 5.4 Comvac 1) .9 Comvac (2) .8 Mincemaster (1) .15Mincemaster (2) .2

While in the foregoing specification we have set out specific procedurein considerable detail for the purpose of illustrating embodiments ofthe invention, it will be understood that such details may be variedwidely by those skilled in the art without departing from the spirit ofour invention.

We claim:

1. In a process for forming a heat-stable sausage emulsion in which meatcontaining protein fibers encased in membranes is mixed with fat, saltand water, the steps of abrading said meat to rupture said membranes andto expose said fibers to the action of said salt for the extraction ofsalt-soluble protein with the result that said fat is smeared in acontinuous phase, and shearing said fat without abrasion to distributesaid fat as particles in a discontinuous phase in said mixture, wherebysaid particles are coated by said extracted protein.

2. The process of claim 1 in which said extraction of salt-solubleprotein is carried out under vacuum.

3-. A process for forming an emulsion, comprising passing meatcontaining fat and protein fibers encased in membranes between disksrotating with respect to each other to abrade said membranes and exposesaid fibers to the action of salt for the extraction of protein whilesmearing said fat into continuous phase, and passing the resultingmixture through apertures of a plate while moving a knife along thesurface of the plate and across the edges of said apertures to cut thefat without abrasion into discontinuous particles within the mixture,whereby said particles are coated by said extracted protein.

References Cited UNITED STATES PATENTS Re. 24,683 8/1959 Schnell 99109X3,095,022 6/1963 Schmook 146-492 5 3,221,788 12/1965 Hughes 146182FOREIGN PATENTS 980,869 1/1965 Great Britain 99-409 10 HYMAN LORD,Primary Examiner US. Cl. X.R.

